Microfiber velvet sponge and methods of making the same

ABSTRACT

A cosmetic product for operating makeup actions on a user&#39;s face, including at least one base; and at least one microfiber layer covering at least a portion of an outer surface of the base as micro brushes.

PRIORITY STATEMENT

This application claims is a continuation application of and claims the benefit of U.S. patent application Ser. No. 16/147,744, entitled MICROFIBER VELVET SPONGE AND METHODS OF MAKING THE SAME, filed on Sep. 29, 2018. The contents of which incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to cosmetic products. Specifically, the present disclosure relates to microfiber velvet sponge for applying and removing makeups and methods of making the same.

BACKGROUND

Brushes and cosmetic blenders (e.g., cosmetic wipes, cotton pads, or cosmetic sponges) are commonly used to apply makeups on faces of a user. They are normally used to apply both liquid forms of makeups (e.g., foundation liquid) and powder makeups (e.g., eye shadow) on the user's face. While the brushes are only used to apply liquid and powder makeups, cosmetic wipes, cotton pads, and sponges are also used to remove makeups on the user's face. However, the current available blenders, which are made of sponges or cotton pads, are highly absorptive to the liquid makeups, thereby cause high waste rate to the makeups. Therefore, there is a need to provide a new cosmetic product to combine functions of both the brushes and the cosmetic sponge.

SUMMARY

The present application discloses cosmetic products that combine the functions of a brush and a cosmetic blender. The cosmetic product may include a sponge base and a velvet-feeling layer of micro-brushes covering a portion of or substantially an entire outer surface of the sponge base. The layer of micro-brushes may include a cured glue as substrate and a plurality of microfibers between 0.1 mm and 1 mm in length adhered to the substrate. Each microfiber may have one end thereof glued to the substrate and the other end thereof freely pointing outwardly with respect to the outer surface of the base. Accordingly, the sponge base may serve as a cosmetic sponge, meanwhile the micro-brushes layer may serve as cosmetic brushes with super short hairs. Because the shape of the micro-brushes follows or is substantially the same as the shape of the sponge base, the micro-brushes are more effective than conventional cosmetic brushes when applying makeups to corners and contours of a user's face. Further, the layer of microfiber may serve as a waterproof layer to prevent a substantial portion of liquid makeup from being absorbed by the sponge, thereby functioning like a combination of cosmetic sponges and brushes. As a result, the cosmetic product in the present disclosure wastes much less makeups.

The present application also discloses methods of manufacturing the cosmetic products. To manufacture the cosmetic product, a bold sponge base with predetermined shape is first sprayed with a thin but even layer of glue by a glue gun. Before the glue dries or cured, the sponge is then placed in a chamber where plenty of microfibers are blow into and chaotically fly in the air. When the microfibers touch the outer surface of the bold sponge, they are subsequently adhered by the glue. The bold sponge is then move to a second chamber to cure the glue.

According to an aspect of the present disclosure, a cosmetic product for operating makeup actions on a user's face, including at least one base; and at least one microfiber layer covering at least a portion of an outer surface of the base.

The base includes a first elastic material, wherein the first elastic material is porous and substantially deforms when a user uses the cosmetic product to apply or remove makeups from a skin of the user. The first elastic material includes at least one of a sponge or a piece of PU. The first elastic material forms the outer surface of the base material; and the base includes a second elastic material forming a core of the base material.

The at least one microfiber layer includes a plurality of microfibers connected to a substrate layer, forming a layer of micro-brushes. The substrate includes a layer of cured glue, so that the plurality of microfibers is adhered to the substrate layer. Each microfiber of the layer of micro-brushes includes a first end and a second end, the first end connects to the substrate layer, and the second end freely point outward with respect to the outer surface of the base. The at least one microfiber layer prevents a liquid from being substantially absorbed into the base.

According to another aspect of the present disclosure, there is provided a method of manufacturing the cosmetic product, the method including: applying a layer of the glue in liquid form on the outer surface of the base; applying a layer of microfibers on the layer of the glue; and curing the layer of glue.

Additional features will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following and the accompanying drawings or may be learned by production or operation of the examples. The features of the present disclosure may be realized and attained by practice or use of various aspects of the methodologies, instrumentalities and combinations set forth in the detailed examples discussed below.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure is further described in terms of exemplary embodiments. These exemplary embodiments are described in detail with reference to the drawings. These embodiments are non-limiting exemplary embodiments, in which like reference numerals represent similar structures throughout the several views of the drawings, and wherein:

FIG. 1 is a schematic diagram illustrating an exemplary structure of a cosmetic product according to embodiments of the present disclosure;

FIG. 2 illustrates an exemplary shape of a base according to the embodiments of the present disclosure;

FIG. 3 illustrates another exemplary shape of the base according to the embodiments of the present disclosure;

FIG. 4 illustrates yet another exemplary shape of the base according to the embodiments of the present disclosure; and

FIG. 5 is a flowchart showing an exemplary procedure to manufacture a cosmetic product according to the embodiments of the present disclosure.

DETAILED DESCRIPTION

The following description is presented to enable any person skilled in the art to make and use the present disclosure, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present disclosure. Thus, the present disclosure is not limited to the embodiments shown, but is to be accorded the widest scope consistent with the claims.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The term “on” may be intended to indicate any possible location relations that can be described as “on.” For example, when the disclosure states “A is on B,” the statements may be intended to include both “A is directly on B” and “A is on B with some other elements in between.” It will be further understood that the terms “comprise,” “comprises,” and/or “comprising,” “include,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

These and other features, and characteristics of the present disclosure, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, may become more apparent upon consideration of the following description with reference to the accompanying drawings, all of which form a part of this disclosure. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended to limit the scope of the present disclosure. It is understood that the drawings are not to scale.

The flowcharts used in the present disclosure illustrate operations of methods according to some embodiments in the present disclosure. It is to be expressly understood that the operations of the flowchart may be implemented not in order. Conversely, the operations may be implemented in inverted order, or simultaneously. Moreover, one or more other operations may be added to the flowcharts. One or more operations may be removed from the flowcharts.

FIG. 1 is a schematic diagram illustrating an exemplary structure of a cosmetic product for spreading and/removing makeups on a user's face, according to embodiments of the present disclosure. The cosmetic product 100 may include at least one base 110 and at least one microfiber layer 130 covering at least a portion of an outer surface 120 of the base.

The base 110 may be made of an elastic and/or porous material. The base 110 may be soft enough and elastic enough so that the base 110 substantially deforms when a user holds the base 110 and exert a pressure against her/his skin to apply or remove makeups, and the base 110 may restore its original shape when the user withdraws the exerted pressure. For example, the base 110 may be made of sponge, PU, Latex, wood cellulose polymers, and other sponge-like materials. When the sponge and/or PU becomes wet, the sponge and/or PU may become softer, thereby easier to use as a makeup blender.

In some embodiments, the base 110 may be of a composite structure having a layer of sponge-like materials being the outside layer. For example, the base 110 may include a soft rubber core and a sponge layer covering the rubber.

The base 110 may be of a predetermined shape suitable for applying and removing makeups on a user's face. FIG. 2 illustrates an exemplary shape of the base 110 according to the embodiments of the present disclosure. The exemplary base 110 may be a modified dewdrop-shaped base 200 that includes a dewdrop-shaped body 210 with a curved outer surface, configure to be hold in a hand of a user; a tip 220 protruding out from a top of the body 210; a flat surface 230 passing through the tip 220 with a predetermined angle with respect to a central axis of the body 210; and a bottom surface 240 on an opposite side of the tip 220.

The tip 220 may be configured to apply and/or remove liquid and/or powder makeups to and/or from the hard-to-reach corners and/or contours of the user's face. The flat surface 230 may be configured to apply and/or remove liquid and/or powder makeups to and/or from other easy-to-reach parts of the user's face. A portion of the curved outer surface of the dewdrop body 210 may also be used to apply and/or remove liquid and/or powder makeups to and/or from the user's face. The tip 220, the flat surface 230, the above-mentioned portion of the curved outer surface of the dewdrop body 210, or any combination thereof may be working surface of the base 110. Further, the bottom surface 240 may be configured to enable the cosmetic product to sit on a place. The bottom surface 240 may be a flat surface or maybe a curved surface with a same or different curvature from the curved outer surface of the body 210. The bottom surface 240 may serve as a surface for the base 200 to sit on a place.

FIG. 3 illustrates another exemplary shape of the base 110 according to the embodiments of the present disclosure. The exemplary base 110 may be a modified gourd-shaped base 300 that includes a gourd-shaped body 310 with a curved outer surface, configured to be held in a hand of the user; a tip 320 protruding out from a top of the body 310; a flat surface 330 passing through the tip 320 with a predetermined angle with respect to a central axis of the body 310; and a bottom surface 340 on an opposite side of the tip 320.

The tip 320 may be configured to apply and/or remove liquid and/or powder makeups to and/or from the hard-to-reach corners and/or contours of the user's face. The flat surface 330 may be configured to apply and/or remove liquid and/or powder makeups to and/or from other easy-to-reach parts of the user's face. A portion of the curved outer surface of the dewdrop body 310 may also be used to apply and/or remove liquid and/or powder makeups to and/or from the user's face. The tip 320, the flat surface 330, the above-mentioned portion of the curved outer surface of the dewdrop body 310, or any combination thereof may be working surface of the base 110. Further, the bottom surface 340 may be configured to enable the cosmetic product to sit on a place. The bottom surface 340 may be a flat surface or maybe a curved surface with a same or different curvature from the curved outer surface of the body 310. The bottom surface 340 may serve as a surface for the base 300 to sit on a place.

FIG. 4 illustrates yet another exemplary shape of the base 110 according to the embodiments of the present disclosure. The exemplary base 110 may be a missing piece dewdrop-shaped base 400 that includes a bottom surface 440; a dewdrop-shaped body 410 with a curved outer surface, a first flat surface 432 on an upper part of the body 410 with a first predetermined angle with respect to a central axis of the body 410; a second flat surface 434 on the upper part of the body 410 with a second predetermined angle angel with respect to a central axis of the body 410. The second predetermined angle may be different from the first predetermined. The first flat surface 432 may locate on the upper part of the body 410 higher than the second flat surface 434. Consequently, the first flat surface 432 may cross the second flat surface 434 to form a first ridge 450. Further, the first flat surface 440 may cross the curved outer surface of the missing piece dewdrop-shaped base 400 to form a second ridge 420.

The first ridge 450 and/or second ridge 420 may be configured to apply and/or remove liquid and/or powder makeups to and/or from the hard-to-reach corners and/or contours of the user's face. The first and second flat surfaces 432 434 may be configured to apply and/or remove liquid and/or powder makeups to and/or from other easy-to-reach parts of the user's face. A portion of the curved outer surface of the dewdrop body 410 may also be used to apply and/or remove liquid and/or powder makeups to and/or from the user's face. The first ridge 450 and/or the second ridge 420, the first flat surface 432, the second flat surface 434, the above-mentioned portion of the curved outer surface of the dewdrop body 410, or any combination thereof may be working surface of the base 110. Further, the bottom surface 440 may be configured to enable the cosmetic product to sit on a place. The bottom surface 440 may be a flat surface or maybe a curved surface with a same or different curvature from the curved outer surface of the body 410. The bottom surface 440 may serve as a surface for the base 400 to sit on a place.

Referring back to FIG. 1, the microfiber layer 130 may cover a portion of the outer surface 120 of the base 110. In some embodiments, the microfiber layer 130 may cover a substantial portion of the working surface of the base 110. In some other embodiments, the microfiber layer 130 may cover part of or all working surface of the base 110. In yet some other embodiments, the microfiber layer 130 may cover substantially an entire outer surface of the base 110. In other embodiments, the microfiber layer 130 may cover the entire outer surface of the base 110.

The microfiber layer 130 may include a substrate 132 and a layer of microfibers 134 connected to the substrate 132. For example, the substrate may be a thin layer of cured glue, and the plurality of microfibers is adhered to the cured glue layer.

The plurality of microfibers may include, at least in part or wholly, synthetic microfiber material. The term “microfibers” may refer to small diameter fibers having an average diameter not greater than about 75 microns, for example, having an average diameter of from about 1 micron to about 50 microns, or more particularly, having an average diameter of from about 1 micron to about 30 microns. The term “microfiber” here is applied to fabrics, cloths, and materials that are used in the fabrication of synthetic and/or natural microfiber fabric materials, in one aspect, the present invention relates to the use of synthetic microfiber materials including, but not limited to, microfiber made from synthetic polymers, e.g. polyesters, polyamides (e.g. nylon, Kevlar, Nomex, iron and mixtures thereof, Microfiber(s) and fabrics thereof may also includes natural materials such as but not limited to, silk, bamboo, cotton, flax, hemp, jute, kapok, wool, and other animal fur.

As used herein the term “Nylon” may refer to polymer polyamides which can be obtained, for example, by the condensation polymerization reaction of a polyacid and a polyamine. Examples of various forms of nylon include nylon-6,6 [also known as poly(hexamethylene adipamide)]; nylon-6,10 [poly(hexamethylene sebacamide)]; nylon-6 [poly(pentamethylene carbonamide)]; nylon-11 [poly(decamethylene carbonamide)]; MXD-6 [poly(meta-xylene adipamide)]; PACM-9 [bis(para-aminocyclohcxyl)methane azelamide]; PACM-10 [bis(para-aminocyclohexyl)-methane sebacamide] and PACM-12 [bis(para-aminocyclohexyl)methane dodecanoamide]. Methods for preparing these nylon-type polyamides are well known to the skilled artisan. Preferably, the co-polymer includes nylon-6 which can be prepared, for example, by the polymerization of caprolactam.

The plurality of microfibers may have an average length h between 0 mm and 2 mm. For example, the plurality of microfibers may have an average length between 0.1 mm and 1 mm, or more particularly, the plurality of microfibers may have an average length between 0.1 mm and 1 mm.

In some embodiments, at least a portion of the plurality of microfibers may have one end glued to the substrate and the other end thereof freely pointing outwardly with respect to the outer surface 120 of the base 110. In some embodiments, all or substantially all of the plurality of microfibers may have one end glued to the substrate and the other end thereof freely pointing outwardly with respect to the outer surface 120 of the base 110. Accordingly, the microfiber layer 130 may be a layer of micro-brushes with super short hairs, and may resemble and touch like a velvet layer.

Because the shapes of the micro-brushes follows the shape of the sponge base 110, the shape of the micro-brush is substantially the same of the sponge base 110. Therefore, the micro-brushes are more effective than conventional cosmetic brushes when applying makeups to corners and contours of a user's face.

Further, because the sponge base 110 is covered by a layer of micro-brushes 134, the sponge base 110 may demonstrate better performance than the conventional cosmetic sponge. For example, the layer of microfiber 130 may serve as a waterproof layer to prevent a substantial portion of liquid makeup from being absorbed by the sponge base 110, thereby behaving like a cosmetic blender that wastes much less makeups.

FIG. 5 illustrates a flow chart of manufacturing the cosmetic product shown in FIG. 1. The manufacturing process 500 may be performed by a machine including a conveyor belt to ride a sponge base 110 to go through the entire manufacturing process shown below; a glue gun having at least one nozzle to spray glue; a first chamber to apply the microfibers on the sponge base 110; and a second chamber to bake or cure the glue.

In Step 510, placing a bold sponge base 110 on the conveyor belt.

To this end, the conveyor belt may include a plurality of sticks pointing upward with a sharp tip to penetrate into the bottom surface of the base 110. Each of the plurality of sticks connects to a motor so that the sponge base 110 may rotate at a constant speed during the manufacturing procedure 500.

In Step 520, applying a layer of the glue in liquid form on the outer surface of the base.

To this end, one or more nozzles may be arranged beside the conveyor belt and constantly spray mists of liquid glue to the conveyor. When the sponge base 110 passes through the nozzle, and through constant rotation of the sticks, the micro-droplets of glue in the mists may evenly deposit on the sponge base 110 to form a thin and even layer of liquid glue.

In Step 530, applying an even layer of microfibers on the liquid glue layer.

The sponge base 110 with the thin layer of liquid glue is subsequently bring to a first chamber to deposit the layer of microfibers 134. The first chamber may include an inlet to blow air into the first chamber to generate turbulent airflow. Microfibers are also supplied into the first chamber at a predetermined speed. Consequently, the microfibers may fly together with the turbulent air flow. When the sponge base 110 enters in to the first chamber, part of the microfibers may be adhered by the liquid glue to form the layer of microfibers evenly.

In Step 540, curing the layer of glue. The sponge base with the layer of microfibers are delivered to a second chamber to bake or cure the glue.

Having thus described the basic concepts, it may be rather apparent to those skilled in the art after reading this detailed disclosure that the foregoing detailed disclosure is intended to be presented by way of example only and is not limiting. Various alterations, improvements, and modifications may occur and are intended to those skilled in the art, though not expressly stated herein. These alterations, improvements, and modifications are intended to be suggested by this disclosure, and are within the spirit and scope of the exemplary embodiments of this disclosure. For example, while the device and method in the present disclosure is described primarily in regard to the cosmetic product and method of manufacturing thereof, it should also be understood that this is only one exemplary embodiment. The spirit of the device or method of manufacturing the same in the present disclosure may be applied to any other kind of on demand service. For example, the device or method of the present disclosure may be applied to wipes of other commodities, such as wipes in kitchen or window wipes.

Moreover, certain terminology has been used to describe embodiments of the present disclosure. For example, the terms “one embodiment,” “an embodiment,” and/or “some embodiments” mean that a particular feature, structure or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Therefore, it is emphasized and should be appreciated that two or more references to “an embodiment” or “one embodiment” or “an alternative embodiment” in various portions of this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures or characteristics may be combined as suitable in one or more embodiments of the present disclosure.

Furthermore, the recited order of processing elements or sequences, or the use of numbers, letters, or other designations therefore, is not intended to limit the claimed processes and methods to any order except as may be specified in the claims. Although the above disclosure discusses through various examples what is currently considered to be a variety of useful embodiments of the disclosure, it is to be understood that such detail is solely for that purpose, and that the appended claims are not limited to the disclosed embodiments, but, on the contrary, are intended to cover modifications and equivalent arrangements that are within the spirit and scope of the disclosed embodiments.

Similarly, it should be appreciated that in the foregoing description of embodiments of the present disclosure, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure aiding in the understanding of one or more of the various embodiments. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, claimed subject matter may lie in less than all features of a single foregoing disclosed embodiment. 

1. A cosmetic blender, comprising: a sponge base; and a microfiber layer covering at least a portion of an outer surface of the sponge base.
 2. The cosmetic blender of claim 1, wherein the microfiber layer includes artificial velvet layer configured to pick up makeups material.
 3. The cosmetic blender of claim 2, wherein the makeups material is in at least one of liquid form or powder form.
 4. The cosmetic blender of claim 2, wherein the artificial velvet layer includes a plurality of microfibers.
 5. The cosmetic blender of claim 4, wherein the plurality of microfibers includes fibers having an average diameter smaller than 75 microns.
 6. The cosmetic blender of claim 4, wherein the plurality of microfibers includes fibers having an average length between 0 mm and 2 mm.
 7. The cosmetic blender of claim 4, wherein the plurality of microfibers is made of at least one of polyester, polyamide, silk, bamboo, cotton, flax, hemp, jute, kapok, wool or animal fur.
 8. The cosmetic blender of claim 4, wherein the velvet layer includes a layer of micro-brushes.
 9. The cosmetic blender of claim 8, wherein each microfiber of the layer of micro-brushes includes a first end and a second end, the first end connects to the outer surface of the sponge base, and the second end freely point outward with respect to the outer surface of the sponge base.
 10. The cosmetic blender of claim 9, further comprising a substrate layer between the plurality of microfibers and the sponge base, wherein the first end connects to the outer surface of the sponge base includes the first end connects to the substrate layer.
 11. The cosmetic blender of claim 10, wherein the substrate layer includes a layer of cured adhesive material, so that the plurality of microfibers is adhered to the substrate layer.
 12. The cosmetic blender of claim 10, wherein the at least one layer of microfiber is formed by a process including: applying a layer of the adhesive material in liquid form on the outer surface of the sponge base; applying a layer of microfibers on the layer of the adhesive material; and curing the layer of adhesive material.
 13. The cosmetic blender of claim 12, wherein the applying of the layer of the adhesive material on the outer surface of the sponge base includes: depositing micro-droplets of the liquid adhesive material evenly on the outer surface of the sponge base.
 14. The cosmetic blender of claim 12, wherein the applying of the layer of microfibers on the layer of the adhesive material includes: placing the sponge base in a chamber; depositing the plurality of microfibers evenly on the layer of liquid adhesive material.
 15. The cosmetic blender of claim 1, wherein the sponge base includes: a body configure to be held in a hand of a user; and at least one of: a tip protruding from the body to reach at least one of corners or contours of a user's face; an edge protruding from the body to reach the at least one of corners or contours of the user's face; a first surface to apply and spread makeups on at least a portion of the user's body; or a second surface to sit on a place.
 16. The cosmetic blender of claim 15, wherein the sponge base includes at least one of: a substantial dewdrop shape; or a substantial gourd shape.
 17. The cosmetic blender of claim 2, wherein the artificial velvet layer is a waterproof layer to prevent a substantial portion of a liquid from being absorbed by the sponge base. 